1 00:00:02,000 --> 00:00:03,040 Coffee - every year, 2 00:00:03,040 --> 00:00:09,000 we grind our way through more than 200 million kilos of the stuff. 3 00:00:09,000 --> 00:00:13,800 Together, we get through 55 million cups a day. 4 00:00:13,800 --> 00:00:17,840 Tonight, we are going to reveal the astonishing process 5 00:00:17,840 --> 00:00:19,880 that turns green beans... 6 00:00:19,880 --> 00:00:22,240 ..into instant coffee. 7 00:00:22,240 --> 00:00:25,520 Quenching our thirst is clearly a big job. 8 00:00:25,520 --> 00:00:29,000 This enormous factory is almost half a mile across. 9 00:00:32,680 --> 00:00:34,160 I'm Gregg Wallace... 10 00:00:34,160 --> 00:00:35,760 I love this stuff! 11 00:00:35,760 --> 00:00:37,080 ..and I'm chilling out, 12 00:00:37,080 --> 00:00:40,040 discovering the secrets of freeze-drying coffee... 13 00:00:40,040 --> 00:00:43,680 It's like part adventurous and part very scary. 14 00:00:43,680 --> 00:00:47,520 ..and finding out how they get that freshly brewed aroma... 15 00:00:47,520 --> 00:00:48,920 I recognise that. 16 00:00:48,920 --> 00:00:50,280 ..in every cup. 17 00:00:50,280 --> 00:00:52,320 Does seems strange, you have to take the smell out 18 00:00:52,320 --> 00:00:54,000 and put it back in again. 19 00:00:54,000 --> 00:00:55,760 I'm Cherry Healey. 20 00:00:55,760 --> 00:00:58,080 So, this is my brain. 21 00:00:58,080 --> 00:01:00,960 I'm going cold turkey on caffeine... 22 00:01:00,960 --> 00:01:02,960 I'm so sleepy. 23 00:01:02,960 --> 00:01:05,680 It's half-past eight! 24 00:01:05,680 --> 00:01:09,360 ..and exploring the future of the coffee plant. 25 00:01:09,360 --> 00:01:10,840 It's not good news, I'm afraid. 26 00:01:10,840 --> 00:01:15,160 In many cases, we've seen arabica dying in Ethiopia. 27 00:01:15,160 --> 00:01:18,240 And historian Ruth Goodman goes back in time... 28 00:01:18,240 --> 00:01:20,840 Eugh, that's foul! 29 00:01:20,840 --> 00:01:24,200 ..and lifts the lid on the world's first instant coffee. 30 00:01:24,200 --> 00:01:26,560 It looks rather like axle grease. 31 00:01:28,120 --> 00:01:30,800 Tonight, we spill the beans 32 00:01:30,800 --> 00:01:36,200 on how this factory makes 175,000 jars of instant coffee 33 00:01:36,200 --> 00:01:37,760 every 24 hours. 34 00:01:37,760 --> 00:01:38,960 Cheers! 35 00:01:38,960 --> 00:01:41,520 Welcome to Inside The Factory. 36 00:02:06,920 --> 00:02:10,320 This is the Nestle factory in South Derbyshire. 37 00:02:10,320 --> 00:02:12,640 890 people work here, 38 00:02:12,640 --> 00:02:15,440 making instant coffee and coffee pods. 39 00:02:24,280 --> 00:02:26,440 Tonight, we're following the production 40 00:02:26,440 --> 00:02:28,320 of freeze-dried instant coffee. 41 00:02:32,440 --> 00:02:35,400 It all starts with a delivery of coffee beans. 42 00:02:41,280 --> 00:02:44,600 Overseeing this morning's shipment is Robbie Hickinson. 43 00:02:45,760 --> 00:02:48,640 Robbie, thank you very much for showing me around. 44 00:02:48,640 --> 00:02:52,280 It's no problem. So, this is where it all starts, right? 45 00:02:52,280 --> 00:02:54,080 This is green bean reception. 46 00:02:54,080 --> 00:02:56,040 How many beans on that truck? 47 00:02:56,040 --> 00:03:00,440 27 tonnes of arabicas from Brazil. 48 00:03:00,440 --> 00:03:02,680 If that's arabica, how many types are there? 49 00:03:02,680 --> 00:03:06,560 Two - robustas, arabicas, and we have to use both sorts. 50 00:03:06,560 --> 00:03:10,120 One gives it the body, and the other one gives it the fruitiness. 51 00:03:10,120 --> 00:03:14,360 Right now, we've got to unload 27 tonnes of these from South America. 52 00:03:18,560 --> 00:03:21,840 The truck is connected up, and unloading begins. 53 00:03:24,000 --> 00:03:27,320 The countdown from beans to jars starts now. 54 00:03:32,440 --> 00:03:35,520 It'll take two hours for this lot to pour into the factory. 55 00:03:40,360 --> 00:03:42,520 When you say green beans, I think about me dinner. 56 00:03:42,520 --> 00:03:43,560 Can I have a look? 57 00:03:49,240 --> 00:03:51,320 They are not green - they are grey! 58 00:03:51,320 --> 00:03:53,800 Next, you're going to be telling me they're not really beans. 59 00:03:53,800 --> 00:03:55,680 Not really, no. They're not, are they? 60 00:03:55,680 --> 00:03:57,440 No. Not really. HE LAUGHS 61 00:03:57,440 --> 00:03:58,720 It's what we call them. 62 00:03:58,720 --> 00:04:01,920 What they actually are, they're the seed of a coffee cherry. 63 00:04:05,040 --> 00:04:07,840 And guess what - they're not even cherries. 64 00:04:09,880 --> 00:04:13,080 The bright red fruit of the coffee plant looks like a cherry 65 00:04:13,080 --> 00:04:15,160 when it's ripe and ready for harvesting. 66 00:04:17,240 --> 00:04:20,240 Inside each fruit are two seeds. 67 00:04:20,240 --> 00:04:22,560 These are the green coffee beans. 68 00:04:24,480 --> 00:04:28,000 So, how many tonnes will come through here in the course of a day? 69 00:04:28,000 --> 00:04:32,600 Between 75 and 100 tonnes a day, 450 tonnes a week. 70 00:04:33,680 --> 00:04:37,520 That's five deliveries of beans from all over the world 71 00:04:37,520 --> 00:04:39,600 arriving here every day. 72 00:04:40,880 --> 00:04:43,120 27 tonnes of this, unloading. 73 00:04:43,120 --> 00:04:45,400 What exactly are you pouring into? 74 00:04:45,400 --> 00:04:47,200 We have a receiving hopper 75 00:04:47,200 --> 00:04:50,440 that's got a mesh that takes out any big things. 76 00:04:50,440 --> 00:04:56,520 Then they go through a cleaner, where we take out smaller items. 77 00:04:56,520 --> 00:04:58,400 Do you get much debris in there? 78 00:04:58,400 --> 00:04:59,600 We get quite a bit, yeah. 79 00:04:59,600 --> 00:05:00,960 Anything unusual? 80 00:05:00,960 --> 00:05:04,240 We've had iguana, we had a live iguana, 81 00:05:04,240 --> 00:05:06,440 and that ended up at Twycross Zoo. 82 00:05:06,440 --> 00:05:09,520 We've had flip-flops, bullets, knives... 83 00:05:09,520 --> 00:05:11,120 Money. HE LAUGHS 84 00:05:11,120 --> 00:05:13,000 We've had it all - no gold, though! 85 00:05:13,000 --> 00:05:15,120 If you do get another iguana, though, give me a call. 86 00:05:15,120 --> 00:05:17,360 I will do, yeah, definitely. 87 00:05:17,360 --> 00:05:18,400 You can have it! 88 00:05:24,200 --> 00:05:26,240 Well, we've got our main ingredient, 89 00:05:26,240 --> 00:05:28,600 but it's missing that wonderful aroma. 90 00:05:28,600 --> 00:05:31,360 To get that, these beans needs to be roasted. 91 00:05:31,360 --> 00:05:34,880 Cherry has been checking out the chemistry that creates our coffee. 92 00:05:40,680 --> 00:05:45,200 Whether you buy instant, filter or freshly ground, 93 00:05:45,200 --> 00:05:47,200 all coffees are roasted. 94 00:05:48,200 --> 00:05:54,560 Each of these packets gives a roast level, so light, medium or dark. 95 00:05:54,560 --> 00:05:59,720 Then there are city roasts, French roasts and Italian roasts. 96 00:06:00,720 --> 00:06:03,640 I want to understand what the differences are, 97 00:06:03,640 --> 00:06:07,520 so I've come to Bath to meet three-time UK barista champion 98 00:06:07,520 --> 00:06:12,360 Maxwell Colonna-Dashwood for a coffee-roasting masterclass. 99 00:06:12,360 --> 00:06:13,760 Hi, Maxwell! 100 00:06:13,760 --> 00:06:15,600 Hello, Cherry. So, what is this? 101 00:06:15,600 --> 00:06:18,000 What is this contraption? So, this is a siphon, 102 00:06:18,000 --> 00:06:19,520 but I'm going to bring it down now, 103 00:06:19,520 --> 00:06:21,360 and then we can make you a cup of coffee. 104 00:06:21,360 --> 00:06:24,120 To begin with, Maxwell wants me to taste coffee 105 00:06:24,120 --> 00:06:26,360 made from unroasted green beans. 106 00:06:27,960 --> 00:06:29,800 Cheers. Cheers. 107 00:06:29,800 --> 00:06:30,840 To a first. 108 00:06:33,400 --> 00:06:37,080 So, it definitely doesn't have as much flavour or as much punch. 109 00:06:37,080 --> 00:06:39,880 It's more of a flavoured water. 110 00:06:39,880 --> 00:06:42,280 Yeah, it just sort of tastes like grassy water, doesn't it? 111 00:06:42,280 --> 00:06:45,480 So, is this why you roast coffee beans? 112 00:06:45,480 --> 00:06:47,960 Yeah, absolutely. So, then what happens is, when we roast it, 113 00:06:47,960 --> 00:06:50,280 that's when we unlock all of that flavour potential. 114 00:06:52,160 --> 00:06:56,240 Every green coffee bean is packed with natural flavour compounds 115 00:06:56,240 --> 00:06:58,920 that are transformed when they're heated up. 116 00:07:00,280 --> 00:07:04,440 Maxwell's going to roast the same batch of beans to different levels 117 00:07:04,440 --> 00:07:08,000 to show me how their taste and appearance changes. 118 00:07:08,000 --> 00:07:10,080 OK, so... Oh, here we go. 119 00:07:10,080 --> 00:07:13,160 There's the real deal. So, how do we kick this off? 120 00:07:13,160 --> 00:07:16,080 Well, let's do a roast. We put our green coffee in here. 121 00:07:16,080 --> 00:07:17,720 OK. So, let's start it here. 122 00:07:17,720 --> 00:07:19,520 "Roasting start." OK, you can see the... 123 00:07:19,520 --> 00:07:20,880 Oh, there they go! 124 00:07:20,880 --> 00:07:23,360 ..the green coffee drops into the drum. Round and round. 125 00:07:25,000 --> 00:07:30,120 As the beans heat up, the green pigment, chlorophyll, turns yellow, 126 00:07:30,120 --> 00:07:31,400 then brown. 127 00:07:31,400 --> 00:07:34,880 Sugars and proteins break down into new flavour compounds. 128 00:07:36,080 --> 00:07:40,720 Vaporising water forces itself out with an audible pop, 129 00:07:40,720 --> 00:07:43,320 known as the first crack. 130 00:07:43,320 --> 00:07:44,480 COFFEE BEANS CRACKLE 131 00:07:44,480 --> 00:07:47,440 I can definitely hear the first crack, they're jumping about, 132 00:07:47,440 --> 00:07:49,560 and the aroma's much more intense. 133 00:07:51,680 --> 00:07:54,160 We would call this a light roast - a city roast, maybe, 134 00:07:54,160 --> 00:07:55,680 if you're in America. 135 00:07:55,680 --> 00:08:01,480 Now for a medium roast - 12 minutes at 210 degrees C, 136 00:08:01,480 --> 00:08:04,760 which brings out more caramel and chocolate flavours. 137 00:08:06,600 --> 00:08:10,000 With the medium roast, we're going to stop it just before second crack. 138 00:08:10,000 --> 00:08:15,720 The final, or second, crack is caused by a build-up of gases. 139 00:08:15,720 --> 00:08:16,760 Here we go! 140 00:08:19,440 --> 00:08:23,400 Looks slightly shinier than the light roast. 141 00:08:23,400 --> 00:08:28,480 Now for the dark roast - 14 minutes at 235 degrees C. 142 00:08:30,920 --> 00:08:35,600 Acidic molecules in the beans turn into compounds called lactones 143 00:08:35,600 --> 00:08:37,280 which taste bitter. 144 00:08:37,280 --> 00:08:40,000 It's really smoky - is it meant to be that smoky?! 145 00:08:40,000 --> 00:08:42,760 Well, unfortunately, there's no way of roasting dark roast coffee 146 00:08:42,760 --> 00:08:45,400 without creating that amount of smoke. Wow, we've made a really, 147 00:08:45,400 --> 00:08:47,560 really dark roast! This would be a French roast. 148 00:08:47,560 --> 00:08:48,760 Is that not burnt? 149 00:08:48,760 --> 00:08:49,800 I would call it burnt, 150 00:08:49,800 --> 00:08:52,240 but there is a market for coffee this dark out there. 151 00:08:52,240 --> 00:08:54,320 It smells bitter and pungent, 152 00:08:54,320 --> 00:08:56,320 but it's still a coffee smell. 153 00:08:56,320 --> 00:09:00,040 I can definitely really see the difference in oil content. 154 00:09:00,040 --> 00:09:03,280 Absolutely, so during that second crack, the build-up of CO2, 155 00:09:03,280 --> 00:09:05,400 it forced all the oils onto the outside of the bean. 156 00:09:06,680 --> 00:09:10,400 Our three roasts look very different. 157 00:09:10,400 --> 00:09:12,040 But how do they taste? 158 00:09:14,280 --> 00:09:16,800 Maxwell brews up a cup of each one. 159 00:09:18,680 --> 00:09:19,920 This is the light roast. 160 00:09:22,360 --> 00:09:25,360 I didn't think I would like the light brew... Mm-hm. 161 00:09:25,360 --> 00:09:29,200 ..but the flavour's beautiful, and it's not too bitter or punchy. 162 00:09:29,200 --> 00:09:31,600 Often, there is an association that the light roast coffee 163 00:09:31,600 --> 00:09:32,640 is less flavourful, 164 00:09:32,640 --> 00:09:34,880 but actually the idea behind a really good light roast 165 00:09:34,880 --> 00:09:36,680 is to showcase the character of the coffee. 166 00:09:36,680 --> 00:09:38,960 It should have lots of flavour, even though it's light. 167 00:09:38,960 --> 00:09:40,240 So, let's do the medium roast. 168 00:09:40,240 --> 00:09:43,000 So, I would normally go for a medium to dark. 169 00:09:43,000 --> 00:09:45,680 OK. I always just think more is more. 170 00:09:48,400 --> 00:09:49,640 You see, I like that... 171 00:09:49,640 --> 00:09:51,800 Yeah. ..but it's starting to get... 172 00:09:51,800 --> 00:09:54,800 More bitter? A little bit mouthy. 173 00:09:54,800 --> 00:09:56,320 Yeah. And then the dark roast... 174 00:09:59,040 --> 00:10:00,280 SHE SPLUTTERS 175 00:10:00,280 --> 00:10:01,840 HE LAUGHS 176 00:10:01,840 --> 00:10:03,480 Phew, are my eyes watering?! 177 00:10:03,480 --> 00:10:05,360 It's got a really strong aftertaste, as well. 178 00:10:05,360 --> 00:10:08,480 Yeah. And I normally drink mine with quite a lot of milk. 179 00:10:08,480 --> 00:10:09,680 That's a really good point - 180 00:10:09,680 --> 00:10:11,720 so what you liked about the light roast coffee, 181 00:10:11,720 --> 00:10:14,760 the fats in the milk will wipe a lot of that fruity acidity out. 182 00:10:14,760 --> 00:10:16,640 So, this might be a bit weak with milk. 183 00:10:16,640 --> 00:10:21,760 I never drink black coffee, really, because it tastes so bad on its own. 184 00:10:21,760 --> 00:10:25,520 Yes, sure. Actually, I wonder, if I tried to drink light roast 185 00:10:25,520 --> 00:10:27,600 a bit more, I could have it black. 186 00:10:27,600 --> 00:10:30,400 Well, actually, the crusade of a lot of the speciality coffee shops 187 00:10:30,400 --> 00:10:33,040 is getting people to taste the black coffee for that very reason. 188 00:10:33,040 --> 00:10:35,680 I've never had a light roast coffee before, 189 00:10:35,680 --> 00:10:37,280 and I think that is delicious, 190 00:10:37,280 --> 00:10:38,960 and I would have that without milk. 191 00:10:38,960 --> 00:10:40,880 Excellent. Light roast wins. 192 00:10:42,600 --> 00:10:46,800 Ultimately, which roast you prefer is down to personal taste, 193 00:10:46,800 --> 00:10:50,480 but there's so much variety out there, why not experiment? 194 00:10:54,680 --> 00:10:55,920 Back in Derbyshire, 195 00:10:55,920 --> 00:10:59,200 this morning's delivery has been sieved and cleaned 196 00:10:59,200 --> 00:11:01,040 to remove any odd additions. 197 00:11:01,040 --> 00:11:03,360 Thankfully, no iguanas today! 198 00:11:06,200 --> 00:11:09,560 The average coffee bean weighs less than a fifth of a gram, 199 00:11:09,560 --> 00:11:13,200 so they're easily blown around the factory using compressed air. 200 00:11:15,840 --> 00:11:18,760 Our beans have made their way to the roasting area, 201 00:11:18,760 --> 00:11:23,400 where Robbie's waiting for me under 15 metre high silos. 202 00:11:24,720 --> 00:11:30,320 They are ginormous, absolutely ginormous! 203 00:11:30,320 --> 00:11:32,160 How much does each silo weigh? 204 00:11:32,160 --> 00:11:33,960 27 tonnes. 205 00:11:33,960 --> 00:11:35,440 And how many silos? Eight. 206 00:11:37,000 --> 00:11:39,240 That's over 200 tonnes of beans. 207 00:11:39,240 --> 00:11:41,680 That's right, about 216 tonnes. 208 00:11:41,680 --> 00:11:44,240 In normal production, how long would that last you? 209 00:11:44,240 --> 00:11:46,440 Two to three days. You're kidding me! 210 00:11:46,440 --> 00:11:49,120 No, no. We roast a lot of coffee. 211 00:11:49,120 --> 00:11:52,200 How many jars of coffee are we going to make today? 212 00:11:52,200 --> 00:11:53,920 175,000 jars. 213 00:11:56,200 --> 00:11:59,920 That's enough to supply all of Manchester for a month. 214 00:12:02,800 --> 00:12:04,320 So, what we're doing now, 215 00:12:04,320 --> 00:12:07,000 we're going to weigh out a batch of 420 kilos. 216 00:12:07,000 --> 00:12:08,920 So, what do we do, just open one of those hoppers 217 00:12:08,920 --> 00:12:10,360 and drag down some beans? 218 00:12:10,360 --> 00:12:14,560 No, we'll take from five different silos, cos it's a five-bean blend. 219 00:12:15,560 --> 00:12:18,000 And each silo has got a different bean in it? 220 00:12:18,000 --> 00:12:20,560 It's got a different grade of bean. 221 00:12:20,560 --> 00:12:24,040 Every bean that enters the factory is given a grade 222 00:12:24,040 --> 00:12:26,080 according to quality. 223 00:12:26,080 --> 00:12:29,160 Our instant coffee needs five different beans. 224 00:12:30,160 --> 00:12:33,480 They fall from the silos into this giant hopper, 225 00:12:33,480 --> 00:12:36,560 which weighs out 420 kilos. 226 00:12:38,120 --> 00:12:39,840 Shall we have a cup of tea before we go, 227 00:12:39,840 --> 00:12:41,720 or do we get sacked if we have a cup of tea? 228 00:12:44,880 --> 00:12:48,480 The beans are blown 11 metres up to the top of the room 229 00:12:48,480 --> 00:12:50,280 to be prepared for roasting. 230 00:12:52,840 --> 00:12:54,360 If heated too quickly, 231 00:12:54,360 --> 00:12:57,680 compounds in the beans will burn and ruin the flavour, 232 00:12:57,680 --> 00:13:00,320 so they're pre-warmed to 60 degrees C. 233 00:13:02,280 --> 00:13:05,840 After ten minutes, they drop down a floor into the roaster. 234 00:13:09,440 --> 00:13:12,080 They're moving around, it's like a washing machine! 235 00:13:12,080 --> 00:13:14,800 That reminds me of when I used to go to the launderette when I was a kid 236 00:13:14,800 --> 00:13:17,360 with my mum. They won't come out very clean in here. 237 00:13:17,360 --> 00:13:20,280 We've got a stream of air coming in at the bottom of the roaster. 238 00:13:20,280 --> 00:13:22,040 Because of the shape of the roaster, 239 00:13:22,040 --> 00:13:25,480 the beans move up in the air stream and then drop back to the bottom 240 00:13:25,480 --> 00:13:28,600 and keep rotating. Why do you need to move them around? 241 00:13:28,600 --> 00:13:31,400 It gives us a more uniform colour, more even roast. 242 00:13:32,880 --> 00:13:34,960 Our coffee will be a medium roast. 243 00:13:34,960 --> 00:13:38,440 It's popular with consumers and works with or without milk. 244 00:13:40,120 --> 00:13:44,040 How hot is it in there? We finish the temperature at 230 degrees. 245 00:13:44,040 --> 00:13:46,600 It gets hotter as it goes? It progressively gets hotter, yeah. 246 00:13:46,600 --> 00:13:48,280 And how long are they in there for? 247 00:13:48,280 --> 00:13:51,600 Ten minutes. I can feel that extraordinary heat from here. 248 00:13:51,600 --> 00:13:53,080 Yes. Wonderful! 249 00:13:54,440 --> 00:13:56,000 Right, they are now brown, 250 00:13:56,000 --> 00:13:59,120 they've gone from that grey colour to something I would recognise 251 00:13:59,120 --> 00:14:00,880 as a coffee bean, that's brown. 252 00:14:00,880 --> 00:14:02,160 That's a roast coffee, yeah. 253 00:14:02,160 --> 00:14:04,320 What happens to them after ten minutes? 254 00:14:04,320 --> 00:14:05,840 We drop them into the cooler. 255 00:14:05,840 --> 00:14:07,800 Because they come out of here red hot, right? 256 00:14:07,800 --> 00:14:10,120 Red hot. Let's go and have a look, shall we? OK. 257 00:14:13,320 --> 00:14:16,480 The beans drop out of the roaster and down another floor 258 00:14:16,480 --> 00:14:18,760 using only the force of gravity. 259 00:14:24,120 --> 00:14:25,920 It's another washing machine! 260 00:14:25,920 --> 00:14:30,520 This is the cooler. So, it comes down into that at 230 degrees... 261 00:14:30,520 --> 00:14:32,800 Yeah. ..and that's moving around because of air, 262 00:14:32,800 --> 00:14:35,320 the same as the one above. Exactly the same. 263 00:14:35,320 --> 00:14:38,840 And what temperature do you want to get it down to? 40 degrees. 264 00:14:38,840 --> 00:14:40,320 Why do you have to cool it? 265 00:14:40,320 --> 00:14:42,640 If we was to discharge it when it was still hot, 266 00:14:42,640 --> 00:14:45,520 you've got the chance of exothermic reaction in the silos. 267 00:14:45,520 --> 00:14:49,440 What?! Exothermic reaction is where the self-heating of the beans, 268 00:14:49,440 --> 00:14:51,120 they keep on roasting. 269 00:14:51,120 --> 00:14:54,720 Ah... In the end, you could end up with a fire if they get too hot. 270 00:14:54,720 --> 00:14:56,880 Ah! When you take something out of the oven, 271 00:14:56,880 --> 00:14:59,120 people don't realise it's still going to cook. 272 00:14:59,120 --> 00:15:00,880 It still keeps cooking. Residual heat. 273 00:15:00,880 --> 00:15:02,800 Yeah. And now what's going to happen to 'em 274 00:15:02,800 --> 00:15:05,600 when they get to the right temperature? They go to grinding. 275 00:15:05,600 --> 00:15:07,240 Right, that's what I want to see. 276 00:15:08,840 --> 00:15:11,120 Thank you so, so much. You're very welcome. 277 00:15:11,120 --> 00:15:13,080 That was great - I know you're busy, so thank you. 278 00:15:13,080 --> 00:15:14,120 Thank you. 279 00:15:16,200 --> 00:15:19,080 I'm following the beans to the grinding department 280 00:15:19,080 --> 00:15:20,120 just next door... 281 00:15:21,320 --> 00:15:24,840 ..where I'm meeting process specialist Katie Perry. 282 00:15:24,840 --> 00:15:26,720 Katie, I'm Gregg. 283 00:15:26,720 --> 00:15:30,640 What are you now doing with the roasted beans? 284 00:15:30,640 --> 00:15:34,840 So, the roasted beans are fed into this grinder, 285 00:15:34,840 --> 00:15:38,560 and within the grinder we have layers of rollers, 286 00:15:38,560 --> 00:15:43,240 so as we move down the grinder, the rollers are getting closer together, 287 00:15:43,240 --> 00:15:45,720 to grind the bean into a finer and finer particle. 288 00:15:47,240 --> 00:15:48,920 So, these are the roast beans. 289 00:15:48,920 --> 00:15:52,280 Now, that, finally, looks like a coffee bean. 290 00:15:54,400 --> 00:15:56,120 Phwoar! 291 00:15:56,120 --> 00:15:57,880 That'll wake you up in the morning. 292 00:15:59,000 --> 00:16:02,560 So, this is a sample of partway through our grinder. 293 00:16:02,560 --> 00:16:04,960 The smell is getting stronger, but that, yeah, 294 00:16:04,960 --> 00:16:09,400 that is becoming a coarse dust, a dust with crispy bits in. 295 00:16:09,400 --> 00:16:12,000 Yeah. And then our final sample... 296 00:16:13,640 --> 00:16:15,480 This shows you our final grind, 297 00:16:15,480 --> 00:16:17,960 so this is the fine particles of the coffee beans. 298 00:16:17,960 --> 00:16:19,880 And how long does it take? 299 00:16:19,880 --> 00:16:24,840 This grinder will take about 1,500 kilos of beans every hour. 300 00:16:24,840 --> 00:16:28,560 Crying out loud! Can I watch the next stage, please? 301 00:16:28,560 --> 00:16:29,600 Yes, follow me. 302 00:16:32,240 --> 00:16:33,880 Roasted and ground, 303 00:16:33,880 --> 00:16:36,880 we're well on the way to putting coffee in somebody's cup. 304 00:16:41,280 --> 00:16:44,160 For many of us, coffee is a daily habit, 305 00:16:44,160 --> 00:16:47,960 and the modern world is unimaginable without it. 306 00:16:47,960 --> 00:16:49,000 Over to Ruth. 307 00:16:50,920 --> 00:16:52,120 Cheers. 308 00:16:52,120 --> 00:16:55,760 Today, our high streets are bustling with coffee shops, 309 00:16:55,760 --> 00:16:58,000 and they're transforming the way we work - 310 00:16:58,000 --> 00:17:00,200 providing desk space and Wi-Fi 311 00:17:00,200 --> 00:17:03,440 for many of Britain's 2 million freelancers. 312 00:17:04,920 --> 00:17:06,560 But it's not the first time 313 00:17:06,560 --> 00:17:10,120 that coffee has been at the heart of major social change. 314 00:17:11,880 --> 00:17:13,760 To find out where it all began, 315 00:17:13,760 --> 00:17:16,520 I'm heading into the heart of the City of London 316 00:17:16,520 --> 00:17:18,840 to meet historian Dr Matt Green. 317 00:17:20,080 --> 00:17:21,520 Hi, Matt. Hi, Ruth. 318 00:17:21,520 --> 00:17:23,480 How are you? I'm good. 319 00:17:23,480 --> 00:17:26,880 Tell me, when did coffee arrive in this country? 320 00:17:26,880 --> 00:17:30,720 It arrived in this very churchyard in the year 1652. 321 00:17:30,720 --> 00:17:35,040 As early as that? And there was this sort of amazing looking sort of shed 322 00:17:35,040 --> 00:17:38,160 that was decorated in garish Islamic patterning, 323 00:17:38,160 --> 00:17:41,000 and that was the first coffee house in the whole country. 324 00:17:41,000 --> 00:17:43,840 By 1700, there were 3,000 all over the city. 325 00:17:43,840 --> 00:17:45,880 That is really fast, isn't it? 326 00:17:45,880 --> 00:17:47,960 There was a coffee house on every street corner. 327 00:17:47,960 --> 00:17:50,880 It became part of the fabric of urban living. 328 00:17:52,520 --> 00:17:55,160 Although that first coffee to hit our shores 329 00:17:55,160 --> 00:17:57,080 wasn't quite the drink we know today. 330 00:17:58,720 --> 00:18:01,320 So, here we have some authentic 331 00:18:01,320 --> 00:18:06,400 late-17th, early 18th-century coffee for your delectation. 332 00:18:06,400 --> 00:18:08,080 OK. Would you like to try some? 333 00:18:08,080 --> 00:18:09,360 Yeah, yeah, yeah. Go on, then. 334 00:18:09,360 --> 00:18:12,480 Here we go. It might be a bit of a shock. 335 00:18:18,880 --> 00:18:21,400 Oh, it's tough! That is a strong brew. 336 00:18:21,400 --> 00:18:23,000 It is. It's... Bitter. 337 00:18:23,000 --> 00:18:24,720 Industrial strength. 338 00:18:24,720 --> 00:18:26,480 Really packs a punch. 339 00:18:26,480 --> 00:18:29,840 Mmm. Think of this like fuel, the jet fuel of the Enlightenment. 340 00:18:30,880 --> 00:18:35,080 Before the arrival of coffee, we had been a nation of beer drinkers. 341 00:18:35,080 --> 00:18:39,320 Replacing alcohol with caffeine had many advantages, 342 00:18:39,320 --> 00:18:41,480 including clearer heads. 343 00:18:41,480 --> 00:18:45,160 Coffee houses became centres of discussion and debate, 344 00:18:45,160 --> 00:18:48,360 often referred to as penny universities. 345 00:18:48,360 --> 00:18:50,800 Anyone could go in for the price of a penny. 346 00:18:50,800 --> 00:18:54,760 OK. So, you'd walk in, you'd hear the boiling of the coffee cauldron. 347 00:18:54,760 --> 00:18:58,240 Through the haze, you'd see rows of moderately well-dressed men, 348 00:18:58,240 --> 00:19:00,080 sitting around long, wooden tables. 349 00:19:00,080 --> 00:19:03,480 The minute they saw you, they would stop what they were doing, 350 00:19:03,480 --> 00:19:06,480 point in your general direction, and scream out the words, 351 00:19:06,480 --> 00:19:07,680 "What news have you?" 352 00:19:07,680 --> 00:19:09,840 You weren't really allowed to take your place 353 00:19:09,840 --> 00:19:12,920 until you'd divulged some nuggets of news, or gossip or rumour. 354 00:19:14,400 --> 00:19:16,120 But this was more than idle chatter. 355 00:19:17,800 --> 00:19:19,560 These were places of business, 356 00:19:19,560 --> 00:19:23,160 and different coffee houses attracted different clientele. 357 00:19:25,040 --> 00:19:27,720 So, here we are in Exchange Alley, 358 00:19:27,720 --> 00:19:29,840 and there were three very famous coffee houses here 359 00:19:29,840 --> 00:19:31,400 in the 17th and 18th century. 360 00:19:31,400 --> 00:19:34,840 The first one was Jonathan's, which is behind us. 361 00:19:34,840 --> 00:19:37,680 This is where you'd come to trade stocks and shares. 362 00:19:37,680 --> 00:19:42,160 OK. This gave rise to the London Stock Exchange. 363 00:19:42,160 --> 00:19:44,280 Down there, a mere stone's throw away, 364 00:19:44,280 --> 00:19:46,240 you have the site of Lloyds of London. 365 00:19:46,240 --> 00:19:49,440 That's where ship captains and merchants and moneyed men 366 00:19:49,440 --> 00:19:53,600 and insurers would coalesce into Britain's insurance industry. 367 00:19:53,600 --> 00:19:55,280 And you needed a domestic market 368 00:19:55,280 --> 00:19:58,600 for these goods that were being imported from all over the world, 369 00:19:58,600 --> 00:20:01,200 so down here, we have a coffee house called Garraway's, 370 00:20:01,200 --> 00:20:04,600 which was one of the most splendid and most famous coffeehouses. 371 00:20:04,600 --> 00:20:06,640 And this was the eBay of its day, if you like, 372 00:20:06,640 --> 00:20:09,440 where people would have auctions by candlelight. 373 00:20:09,440 --> 00:20:11,360 So, they were just, one, two, three. 374 00:20:11,360 --> 00:20:12,440 One, two, three - 375 00:20:12,440 --> 00:20:14,120 but it was a triptych of coffee houses 376 00:20:14,120 --> 00:20:15,960 which gave birth to modern capitalism. 377 00:20:18,000 --> 00:20:20,600 Coffeehouses were also instrumental in the arrival 378 00:20:20,600 --> 00:20:22,400 of the modern newspaper. 379 00:20:22,400 --> 00:20:24,560 This coffee shop in Covent Garden 380 00:20:24,560 --> 00:20:27,040 is on the site of Button's Coffee House, 381 00:20:27,040 --> 00:20:31,120 established in 1712 by the playwright Joseph Addison 382 00:20:31,120 --> 00:20:32,880 as a home for literary debate. 383 00:20:34,840 --> 00:20:37,360 From here he wrote a newspaper called the Guardian, 384 00:20:37,360 --> 00:20:40,320 which sourced its stories through anonymous notes 385 00:20:40,320 --> 00:20:42,360 posted in the mouth of a golden lion, 386 00:20:42,360 --> 00:20:44,200 which hung on the western wall. 387 00:20:47,360 --> 00:20:51,720 To coffeehouses, changing the world since 1652. 388 00:20:51,720 --> 00:20:54,560 Just think of that, next time you have a sip of your latte. 389 00:21:04,280 --> 00:21:07,920 In the two hours and 38 minutes since our beans arrived... 390 00:21:09,560 --> 00:21:15,200 ..my coffee's been ground and sent to a high-security area 391 00:21:15,200 --> 00:21:16,760 of the factory. 392 00:21:18,360 --> 00:21:20,560 Where are we? What is this? 393 00:21:20,560 --> 00:21:24,040 So, here, Greg, we're in our extraction area - 394 00:21:24,040 --> 00:21:26,040 but this is our top-secret area, 395 00:21:26,040 --> 00:21:29,240 so we can't actually show you any of the technology that we have 396 00:21:29,240 --> 00:21:32,400 just behind the camera - but we'll be able to explain it to you. 397 00:21:34,760 --> 00:21:37,000 As soon as coffee beans are ground, 398 00:21:37,000 --> 00:21:40,880 they release that strong coffee aroma we all know and love. 399 00:21:42,160 --> 00:21:44,960 To make sure it doesn't disappear into thin air, 400 00:21:44,960 --> 00:21:48,720 it's collected using a clever, scientific process. 401 00:21:51,440 --> 00:21:55,040 Nitrogen gas is pumped through the ground coffee, 402 00:21:55,040 --> 00:21:57,600 capturing the aroma as it passes through. 403 00:22:00,640 --> 00:22:03,240 The vapour is stored in a tank for later... 404 00:22:05,160 --> 00:22:07,560 ..while the ground coffee gets brewed up 405 00:22:07,560 --> 00:22:11,680 in a super-sized cafetiere, called a pod. 406 00:22:11,680 --> 00:22:15,040 You might put a couple of scoops into your cafetiere, 407 00:22:15,040 --> 00:22:18,120 but what we're doing is we're putting nearly 700 kilos 408 00:22:18,120 --> 00:22:19,520 into one of our pods. 409 00:22:20,640 --> 00:22:25,440 I reckon, out of this, we could get five cups. 410 00:22:25,440 --> 00:22:27,680 Yeah. How many do get out of your enormous one? 411 00:22:27,680 --> 00:22:30,840 So, each extraction pod that we have would give us 412 00:22:30,840 --> 00:22:33,240 250,000 cups of coffee. 413 00:22:33,240 --> 00:22:35,760 Crying out loud! Where we going to get the biscuits for that? 414 00:22:35,760 --> 00:22:37,200 SHE LAUGHS 415 00:22:37,200 --> 00:22:40,120 If I make a cafetiere, I'm left with bits. 416 00:22:40,120 --> 00:22:43,160 Yes. Now, some people throw them in the bin, 417 00:22:43,160 --> 00:22:45,160 other people throw them in the garden. 418 00:22:45,160 --> 00:22:50,320 What do you do with tonnes and tonnes of coffee bits? 419 00:22:50,320 --> 00:22:52,640 So, all those coffee bits that are left over 420 00:22:52,640 --> 00:22:54,720 are called our spent coffee grounds. 421 00:22:54,720 --> 00:22:57,280 We keep them, squeeze all the water out of them 422 00:22:57,280 --> 00:23:00,320 and then burn them in our boilers to power the factory. 423 00:23:00,320 --> 00:23:03,880 Those coffee grounds produce the same amount of energy as coal. 424 00:23:03,880 --> 00:23:06,400 So, if I stored up all my leftover coffee, 425 00:23:06,400 --> 00:23:08,240 I could put it in my log burner. 426 00:23:08,240 --> 00:23:10,160 Absolutely. Would it really work? 427 00:23:10,160 --> 00:23:14,560 Yeah! You have extracted the aroma. 428 00:23:14,560 --> 00:23:15,800 Yeah. 429 00:23:15,800 --> 00:23:18,120 I know what you do with the bits that are left over, 430 00:23:18,120 --> 00:23:20,680 what do you now do with the liquid? 431 00:23:20,680 --> 00:23:23,520 So, this liquid would go to our evaporation process. 432 00:23:23,520 --> 00:23:24,560 Brilliant. Show me. 433 00:23:26,200 --> 00:23:29,160 So far, we've made coffee as I would at home, 434 00:23:29,160 --> 00:23:31,920 but this is where things change. 435 00:23:31,920 --> 00:23:36,480 Next, this liquid has to be transformed into dry granules. 436 00:23:40,080 --> 00:23:44,480 Right. Where have you poured the enormous pot of coffee? 437 00:23:44,480 --> 00:23:48,120 So, all that coffee extract is now in our evaporator. 438 00:23:48,120 --> 00:23:49,360 An evaporator! 439 00:23:49,360 --> 00:23:50,640 Yes. 440 00:23:50,640 --> 00:23:53,800 That looks like it's going to the floor above. 441 00:23:53,800 --> 00:23:56,800 How high is that? So, this evaporator actually goes up 442 00:23:56,800 --> 00:23:59,480 all six floors of the building that we're in now. 443 00:23:59,480 --> 00:24:00,960 Get out of here! 444 00:24:00,960 --> 00:24:02,240 Really? 445 00:24:03,440 --> 00:24:05,160 No way! 446 00:24:05,160 --> 00:24:06,400 The whole building? 447 00:24:06,400 --> 00:24:07,440 The whole building! 448 00:24:08,880 --> 00:24:11,200 How much coffee is above me? 449 00:24:11,200 --> 00:24:12,640 So, at the moment, 450 00:24:12,640 --> 00:24:15,320 you have about 1 million cups of coffee above you. 451 00:24:15,320 --> 00:24:19,600 If one of those bursts, you and I would melt like sugar cubes. 452 00:24:22,800 --> 00:24:28,400 Every hour, 30,000 litres of coffee travels through heated pipes 453 00:24:28,400 --> 00:24:30,160 inside the tower. 454 00:24:30,160 --> 00:24:36,040 Warmed to 70 degrees C, the water evaporates and is siphoned off. 455 00:24:36,040 --> 00:24:39,880 So, you are reducing your coffee in the same way 456 00:24:39,880 --> 00:24:42,680 that I would reduce a stock at home. 457 00:24:42,680 --> 00:24:46,440 Absolutely. I'd have it in a pot, and the more I heated it, 458 00:24:46,440 --> 00:24:48,240 you would reduce the amount of liquid 459 00:24:48,240 --> 00:24:50,360 but you would concentrate the flavour. Yes. 460 00:24:50,360 --> 00:24:51,600 That's a stock or a sauce. 461 00:24:51,600 --> 00:24:53,880 That's what you're doing with the coffee. Am I right? 462 00:24:53,880 --> 00:24:55,320 Absolutely. 463 00:24:55,320 --> 00:25:00,680 The liquid is reduced by 50%, creating a thick coffee extract. 464 00:25:02,040 --> 00:25:05,640 And how long does it take coffee to go through the tubes? 465 00:25:05,640 --> 00:25:07,960 So, from coffee entering our evaporator, 466 00:25:07,960 --> 00:25:12,200 it will come out as a concentrated extract in about 45 minutes. 467 00:25:12,200 --> 00:25:16,080 If you didn't concentrate it, would that mean, at home, 468 00:25:16,080 --> 00:25:19,600 I would need loads and loads of spoonfuls of coffee? 469 00:25:19,600 --> 00:25:22,760 Would I end up bringing home a jar as big as me? 470 00:25:22,760 --> 00:25:25,720 Well, not quite! If we didn't remove the water from it, 471 00:25:25,720 --> 00:25:27,840 then we wouldn't be able to freeze dry it. 472 00:25:27,840 --> 00:25:31,000 Oh, OK. I just thought it would be much weaker. 473 00:25:31,000 --> 00:25:32,040 HE LAUGHS 474 00:25:34,280 --> 00:25:40,000 Eight hours and 23 minutes in, and we have a 25-metre high tower, 475 00:25:40,000 --> 00:25:43,760 full of hot, highly-concentrated coffee. 476 00:25:43,760 --> 00:25:46,400 Now, that would give you a kick. 477 00:25:46,400 --> 00:25:49,560 The average cup of instant coffee contains 100mg of caffeine, 478 00:25:49,560 --> 00:25:54,440 helping us to get up and get out of the house in the morning. 479 00:25:54,440 --> 00:25:57,160 My mate, Cherry, has been having a go at giving it up. 480 00:26:00,080 --> 00:26:05,040 I love my morning coffee, but for the next five days, 481 00:26:05,040 --> 00:26:10,000 I've agreed to go cold turkey, as part of a scientific experiment. 482 00:26:11,320 --> 00:26:12,520 Before I give up, 483 00:26:12,520 --> 00:26:17,400 I want to understand what caffeine does to my body and brain, 484 00:26:17,400 --> 00:26:20,640 so I'm heading to the University of Bristol 485 00:26:20,640 --> 00:26:24,400 to meet Professor Peter Rogers... and a pineapple. 486 00:26:24,400 --> 00:26:28,040 Peter! Are we having a '70s drinks party? 487 00:26:28,040 --> 00:26:32,040 No, no. This is to show you how caffeine works on your brain. 488 00:26:32,040 --> 00:26:36,800 Caffeine is a psychoactive drug in coffee, tea, cola... 489 00:26:36,800 --> 00:26:38,360 Caffeine is a drug?! 490 00:26:38,360 --> 00:26:41,160 Yes, well, it has psychostimulant effects. 491 00:26:41,160 --> 00:26:42,400 So, this is my brain. 492 00:26:42,400 --> 00:26:45,320 Well, no, actually, this represents a cell in your brain, 493 00:26:45,320 --> 00:26:47,160 and these are receptors. 494 00:26:47,160 --> 00:26:48,800 They're called adenosine receptors. 495 00:26:48,800 --> 00:26:53,920 OK. A molecule, called adenosine, attaches itself to those cells. 496 00:26:53,920 --> 00:26:57,040 Adenosine makes us feel sleepy. 497 00:26:57,040 --> 00:27:02,360 And what caffeine can do is attach itself to the adenosine receptor. 498 00:27:02,360 --> 00:27:04,360 It fits on the receptor like this. 499 00:27:04,360 --> 00:27:06,680 So, what happens then, when adenosine comes along? 500 00:27:06,680 --> 00:27:10,040 It can't attach itself to the ones that are occupied by caffeine. 501 00:27:10,040 --> 00:27:12,200 Oh, I see! So, they take up the seats. 502 00:27:12,200 --> 00:27:14,800 Yes. Which means you're less tired? 503 00:27:14,800 --> 00:27:19,080 It does. But, the alertness created by caffeine isn't permanent. 504 00:27:19,080 --> 00:27:20,960 The body is, in a sense, very clever. 505 00:27:20,960 --> 00:27:24,040 When it's exposed regularly to caffeine, it adapts, 506 00:27:24,040 --> 00:27:26,440 so the receptors become more sensitive, 507 00:27:26,440 --> 00:27:28,080 or there are more of them. 508 00:27:28,080 --> 00:27:30,720 What the body is trying to do is function normally. 509 00:27:30,720 --> 00:27:33,400 Ohhh. Despite caffeine being around. 510 00:27:33,400 --> 00:27:35,320 The more you have, the more you need. 511 00:27:35,320 --> 00:27:38,200 Yes, that's a typical thing that happens with drugs. 512 00:27:38,200 --> 00:27:39,720 You become tolerant. 513 00:27:39,720 --> 00:27:43,160 The other effect is, if you now stop taking the drug, 514 00:27:43,160 --> 00:27:45,120 you're going to feel pretty bad. 515 00:27:45,120 --> 00:27:48,760 What you get is what's called a drug opposite effect. 516 00:27:48,760 --> 00:27:51,040 So, in other words, rather than being more alert, 517 00:27:51,040 --> 00:27:53,760 you're now actually sleepy and fatigued and tired. 518 00:27:53,760 --> 00:27:55,160 So, that's a big downside. 519 00:27:56,800 --> 00:27:59,440 With Peter's warnings ringing in my ears, 520 00:27:59,440 --> 00:28:01,720 I nervously embark on the experiment. 521 00:28:03,320 --> 00:28:06,040 It's Day 1 - I'm allowed caffeine today. 522 00:28:06,040 --> 00:28:10,440 I am savouring every last drop. 523 00:28:10,440 --> 00:28:12,440 So, it's Day 2. 524 00:28:12,440 --> 00:28:14,440 It's a non-caffeine day. 525 00:28:14,440 --> 00:28:16,760 I've got a nice cup of mint tea. 526 00:28:16,760 --> 00:28:18,400 Look at that, hey! 527 00:28:18,400 --> 00:28:22,040 I'm monitoring my blood pressure, tracking my activity, 528 00:28:22,040 --> 00:28:24,200 and recording my mood. 529 00:28:24,200 --> 00:28:26,760 Day 3, I feel rubbish today. 530 00:28:26,760 --> 00:28:28,880 I really can't be bothered with anything. 531 00:28:32,520 --> 00:28:33,720 SHE SIGHS 532 00:28:33,720 --> 00:28:34,840 After five days, 533 00:28:34,840 --> 00:28:38,440 I've re-caffeinated and I'm ready to face my test results. 534 00:28:40,000 --> 00:28:42,640 OK. Woohoo! 535 00:28:42,640 --> 00:28:44,440 So, Cherry, how did you find it? 536 00:28:44,440 --> 00:28:46,360 Not good. Really? 537 00:28:46,360 --> 00:28:48,120 Really, really bad. 538 00:28:48,120 --> 00:28:50,680 OK. Well, that's caffeine cold turkey for you. 539 00:28:50,680 --> 00:28:54,360 Some people even describe it like having flu-like symptoms. 540 00:28:54,360 --> 00:28:56,000 What I want to know is, 541 00:28:56,000 --> 00:28:59,400 do the numbers reflect the drama of the week? 542 00:28:59,400 --> 00:29:03,560 So, these first results are from the alertness ratings you made. 543 00:29:03,560 --> 00:29:08,200 On the Monday, you're less than 40... Yes. in terms of alertness. 544 00:29:08,200 --> 00:29:10,400 When you're withdrawn from caffeine 545 00:29:10,400 --> 00:29:14,000 on Tuesday, Wednesday and Thursday, you're even less alert. 546 00:29:14,000 --> 00:29:15,160 I'm knackered. 547 00:29:15,160 --> 00:29:16,320 Want to get back into bed. 548 00:29:16,320 --> 00:29:19,280 Normally, really full of beans, literally. 549 00:29:19,280 --> 00:29:20,720 It can't be the caffeine... 550 00:29:21,840 --> 00:29:25,960 Without caffeine, more adenosine jumped onto my receptors, 551 00:29:25,960 --> 00:29:27,640 reducing my alertness. 552 00:29:28,920 --> 00:29:32,600 Now, headache is another symptom of caffeine withdrawal. 553 00:29:32,600 --> 00:29:34,080 Thursday, boom. 554 00:29:34,080 --> 00:29:37,240 There it was. Right, right in the middle. 555 00:29:37,240 --> 00:29:41,080 And now I've got the headache, the caffeine headache. 556 00:29:41,080 --> 00:29:42,600 I've taken a couple of painkillers. 557 00:29:42,600 --> 00:29:43,640 It doesn't work. 558 00:29:43,640 --> 00:29:45,400 So, what caffeine normally does 559 00:29:45,400 --> 00:29:47,400 is restrict blood-flow to the brain - 560 00:29:47,400 --> 00:29:49,440 but then when you withdraw caffeine, 561 00:29:49,440 --> 00:29:53,040 you get an increase, above normal, of blood flow to the brain, 562 00:29:53,040 --> 00:29:56,200 and, actually, oddly enough, that's what gives you the headache. 563 00:29:56,200 --> 00:29:58,680 But it's not all bad news. 564 00:29:58,680 --> 00:30:03,560 Results show I slept earlier and for longer on non-caffeine days. 565 00:30:03,560 --> 00:30:05,640 I'm so sleepy. 566 00:30:05,640 --> 00:30:08,320 It's half-past eight! 567 00:30:08,320 --> 00:30:10,840 So, if I don't want to give up my caffeine, 568 00:30:10,840 --> 00:30:14,400 but I do want to be able to sleep easier, what do I do? 569 00:30:14,400 --> 00:30:16,880 For the average person, it takes three to four hours 570 00:30:16,880 --> 00:30:19,520 to eliminate half the amount of caffeine you've consumed 571 00:30:19,520 --> 00:30:20,600 from your body. 572 00:30:20,600 --> 00:30:23,600 So, if I have a cup of tea or coffee at about six o'clock in the evening, 573 00:30:23,600 --> 00:30:25,040 will that affect my sleep? 574 00:30:25,040 --> 00:30:26,720 Yes, it may well do. 575 00:30:26,720 --> 00:30:29,680 It's all left me questioning my long-standing relationship 576 00:30:29,680 --> 00:30:31,000 with caffeine. 577 00:30:31,000 --> 00:30:33,920 Am I not better just kicking the habit completely? 578 00:30:33,920 --> 00:30:36,560 Well, you could do that, or you could keep it in reserve. 579 00:30:36,560 --> 00:30:38,680 So, rather than using it as I do now, 580 00:30:38,680 --> 00:30:41,360 which is just to get through the day, 581 00:30:41,360 --> 00:30:45,640 using it as a back-up for when I really, really need that extra kick? 582 00:30:45,640 --> 00:30:48,320 Yes, and there's also some potentially good news. 583 00:30:48,320 --> 00:30:53,560 There is evidence of a link between a lower risk of Parkinson's disease, 584 00:30:53,560 --> 00:30:56,480 type 2 diabetes, dementia, 585 00:30:56,480 --> 00:31:00,640 even depression amongst people who drink more coffee. 586 00:31:02,280 --> 00:31:04,720 These health benefits have not yet been proven, 587 00:31:04,720 --> 00:31:08,880 and you shouldn't change your coffee habits on this basis - 588 00:31:08,880 --> 00:31:13,000 but I'll certainly be more canny about how I consume caffeine 589 00:31:13,000 --> 00:31:14,200 in the future. 590 00:31:20,640 --> 00:31:23,760 At the factory, our hot, concentrated coffee 591 00:31:23,760 --> 00:31:26,640 is being pumped to the Freezing Department... 592 00:31:30,200 --> 00:31:33,800 ..where the liquid will become solid coffee granules. 593 00:31:37,480 --> 00:31:40,120 In charge is Mike Dale. 594 00:31:40,120 --> 00:31:42,160 Mike. Greg - pleased to meet you. 595 00:31:42,160 --> 00:31:44,640 I've watched the most extraordinary process. 596 00:31:44,640 --> 00:31:47,000 I've seen coffee beans come in green. 597 00:31:47,000 --> 00:31:51,280 OK? I've seen them roasted, cooled down, ground, 598 00:31:51,280 --> 00:31:54,520 then put, basically, in an enormous cafetiere, 599 00:31:54,520 --> 00:31:59,040 and then reduced in the tubes that go over six floors. 600 00:31:59,040 --> 00:32:01,520 Yep. Now what?! So, this is pre-chill. 601 00:32:01,520 --> 00:32:03,400 This is where we pre-chill our coffee, 602 00:32:03,400 --> 00:32:05,120 before it goes into the Cold Room, 603 00:32:05,120 --> 00:32:06,960 and these heat exchanges here 604 00:32:06,960 --> 00:32:10,160 are the same as you would find in an ice cream factory. 605 00:32:10,160 --> 00:32:13,040 So, we are really generating coffee ice cream. 606 00:32:13,040 --> 00:32:15,560 I love coffee ice cream. 607 00:32:15,560 --> 00:32:16,920 Am I able to taste that? 608 00:32:16,920 --> 00:32:18,320 Of course, if you wish. 609 00:32:18,320 --> 00:32:20,200 Have you got any hundreds and thousands? 610 00:32:20,200 --> 00:32:21,960 Not yet! HE LAUGHS 611 00:32:21,960 --> 00:32:26,000 At minus six degrees C, it's more like syrup than ice cream. 612 00:32:28,800 --> 00:32:30,440 Should I dip my...? I should dip. 613 00:32:35,400 --> 00:32:36,800 Yeugh! 614 00:32:37,920 --> 00:32:39,920 Whoa - you said ice cream! 615 00:32:39,920 --> 00:32:43,160 That is like the most concentrated espresso coffee 616 00:32:43,160 --> 00:32:45,040 you've ever had in your life! 617 00:32:45,040 --> 00:32:47,800 That is just strong and bitter. 618 00:32:47,800 --> 00:32:48,920 Yes. You're a nice fellow, 619 00:32:48,920 --> 00:32:51,040 but I'm going to find it hard to trust you from now on. 620 00:32:51,040 --> 00:32:52,240 HE LAUGHS 621 00:32:54,280 --> 00:32:58,720 The coffee's now the correct texture to head into the freezer. 622 00:32:58,720 --> 00:33:00,920 What temperature is the freezer? 623 00:33:00,920 --> 00:33:03,440 The freezer's between -40 and -50 degrees. 624 00:33:04,760 --> 00:33:07,080 Are people allowed in there? Oh, yes. 625 00:33:07,080 --> 00:33:08,640 Can I go in there? We can, 626 00:33:08,640 --> 00:33:10,520 but we need to dress for the occasion. 627 00:33:12,320 --> 00:33:14,920 MUSIC: Also Sprach Zarathustra by Richard Strauss 628 00:33:33,360 --> 00:33:36,120 This doesn't feel anywhere near cold enough. 629 00:33:36,120 --> 00:33:37,680 This isn't -40! 630 00:33:37,680 --> 00:33:38,920 Nope, absolutely, Greg. 631 00:33:38,920 --> 00:33:40,920 This is actually our pre-cool room. 632 00:33:40,920 --> 00:33:43,160 So, what we have is the freezing belt here, 633 00:33:43,160 --> 00:33:46,080 and that is what we freeze the coffee on. 634 00:33:46,080 --> 00:33:49,440 The syrupy coffee is poured on to this conveyor belt 635 00:33:49,440 --> 00:33:51,720 and disappears into the freezer. 636 00:33:51,720 --> 00:33:53,640 WE are going to follow it in... 637 00:33:54,880 --> 00:33:56,360 What we need to do is cover our face, 638 00:33:56,360 --> 00:33:59,120 and I would recommend removing your glasses. Will they freeze? 639 00:33:59,120 --> 00:34:01,160 They will freeze in there, yes. 640 00:34:01,160 --> 00:34:03,880 HE LAUGHS Right, OK! 641 00:34:03,880 --> 00:34:07,800 It's like part adventurous, and part very scary. 642 00:34:07,800 --> 00:34:08,840 Are you ready? 643 00:34:13,080 --> 00:34:14,360 Whoa! 644 00:34:21,480 --> 00:34:25,240 This is the coldest place I've ever been. 645 00:34:25,240 --> 00:34:28,400 The temperature is lower than at the North Pole, 646 00:34:28,400 --> 00:34:30,200 and the noise is deafening. 647 00:34:32,320 --> 00:34:35,440 As the liquid coffee travels along the conveyor belt, 648 00:34:35,440 --> 00:34:39,120 it's blasted with chilly air from above and below. 649 00:34:41,040 --> 00:34:44,080 It takes just two minutes to solidify, 650 00:34:44,080 --> 00:34:49,480 turning it into a solid 8 millimetre thick sheet of frozen coffee. 651 00:34:53,920 --> 00:34:58,200 This feeds into a chipper, which smashes it into icy granules, 652 00:34:58,200 --> 00:35:01,280 each just 2 to 3 millimetres in size. 653 00:35:15,120 --> 00:35:16,480 Whoa! 654 00:35:16,480 --> 00:35:18,400 That is frightening! 655 00:35:18,400 --> 00:35:20,360 That is painful. 656 00:35:20,360 --> 00:35:23,160 That's not like anything on earth. 657 00:35:23,160 --> 00:35:25,280 And this is the result. 658 00:35:25,280 --> 00:35:26,800 You have frozen coffee. 659 00:35:26,800 --> 00:35:28,120 That's off the belt. 660 00:35:28,120 --> 00:35:30,920 That's just before it goes into the breaker 661 00:35:30,920 --> 00:35:33,000 and then into the chipper and grinder. 662 00:35:33,000 --> 00:35:35,920 This is even starting to thaw out outside here. 663 00:35:35,920 --> 00:35:37,400 It's starting to get bendy. 664 00:35:37,400 --> 00:35:39,240 Yep. You'll soon end up with toffee 665 00:35:39,240 --> 00:35:42,080 and then you'll end up with liquor again. You know what? 666 00:35:42,080 --> 00:35:45,040 I think of myself as possibly a bit silly, 667 00:35:45,040 --> 00:35:48,000 because you hear the term freeze-dried, 668 00:35:48,000 --> 00:35:51,560 but you don't ever really consider what that means. 669 00:35:51,560 --> 00:35:55,000 And at the moment, we're only freezing, we're not drying yet. 670 00:35:55,000 --> 00:35:56,280 That's the next step. 671 00:35:58,400 --> 00:36:01,360 In the last eight hours and 37 minutes, 672 00:36:01,360 --> 00:36:05,400 green beans have been transformed into frozen granules. 673 00:36:07,360 --> 00:36:10,240 Despite all these mind-blowing processes, 674 00:36:10,240 --> 00:36:13,000 instant coffee is a convenient and quick way 675 00:36:13,000 --> 00:36:15,320 of getting a brew in your mug - 676 00:36:15,320 --> 00:36:17,840 but when and why was it invented? 677 00:36:26,960 --> 00:36:30,680 Traditionally, making a cup of coffee takes time - 678 00:36:30,680 --> 00:36:32,880 and if you have the time, well, that's all good. 679 00:36:34,960 --> 00:36:37,280 But historically, there have been places 680 00:36:37,280 --> 00:36:39,040 where it wasn't safe to brew up. 681 00:36:40,160 --> 00:36:43,400 On the fields of the American Civil War in the 1860s, 682 00:36:43,400 --> 00:36:47,600 soldiers needed a quicker, more convenient, caffeine hit. 683 00:36:49,240 --> 00:36:52,120 So, the Union Army tested a new coffee essence, 684 00:36:52,120 --> 00:36:54,040 which was beans roasted and ground, 685 00:36:54,040 --> 00:36:57,640 mixed with milk and sugar and the whole lot condensed down 686 00:36:57,640 --> 00:36:59,560 into something that... 687 00:37:02,160 --> 00:37:05,040 ..well, looks rather like axle grease. 688 00:37:06,520 --> 00:37:09,880 We followed the original recipe, so I can try it. 689 00:37:11,920 --> 00:37:16,520 Soldiers would just add boiling water and gave it a stir... 690 00:37:17,840 --> 00:37:20,440 ..to make a sort of instant coffee. 691 00:37:24,200 --> 00:37:25,240 Eurgh! 692 00:37:26,600 --> 00:37:29,640 And it wasn't just Americans who relied on coffee. 693 00:37:29,640 --> 00:37:32,880 It was also a popular choice for us tea-drinking Brits. 694 00:37:34,360 --> 00:37:38,360 Our version of instant coffee was a liquid called Camp, 695 00:37:38,360 --> 00:37:43,000 invented in 1876 and packed off in kit bags in the First World War. 696 00:37:49,040 --> 00:37:51,480 Historian Taff Gillingham wanted to show me 697 00:37:51,480 --> 00:37:53,840 the authentic trench coffee experience. 698 00:37:55,840 --> 00:37:57,520 Hi, Taff. Hi. 699 00:37:57,520 --> 00:37:59,040 Take me through the gates of hell! 700 00:37:59,040 --> 00:38:00,200 Come on! Follow me. 701 00:38:08,360 --> 00:38:10,080 So, here we are. 702 00:38:10,080 --> 00:38:12,080 Do you want to try some? Yeah, all right. 703 00:38:12,080 --> 00:38:13,400 SHE LAUGHS 704 00:38:13,400 --> 00:38:14,960 It's not actually that bad. 705 00:38:14,960 --> 00:38:16,320 You reckon? Yeah. OK. 706 00:38:16,320 --> 00:38:17,360 Let's see... 707 00:38:17,360 --> 00:38:20,080 Or, at least, not if you were living in conditions like this. 708 00:38:22,240 --> 00:38:23,400 Urgh! 709 00:38:23,400 --> 00:38:25,240 Oh, God. That's foul! 710 00:38:25,240 --> 00:38:27,840 Sorry, that was a bit of a shock, how nasty that was! 711 00:38:27,840 --> 00:38:28,880 THEY LAUGH 712 00:38:28,880 --> 00:38:30,960 It's not really coffee at all, that's the trick. 713 00:38:30,960 --> 00:38:32,840 It's got a tiny percentage of coffee in. 714 00:38:32,840 --> 00:38:36,200 It's mostly chicory with sugar, mixed up into a sort of cordial, 715 00:38:36,200 --> 00:38:37,840 which you then added hot water to, 716 00:38:37,840 --> 00:38:41,120 to make some sort of instant, hot, vaguely coffee-tasting drink. 717 00:38:41,120 --> 00:38:43,440 And I suppose it's fairly practical, isn't it? 718 00:38:43,440 --> 00:38:46,200 I mean, it's just a small glass bottle that seals up. 719 00:38:46,200 --> 00:38:48,960 A small bottle like that can be put in one of the fella's packs. 720 00:38:48,960 --> 00:38:50,320 And they drank a lot of it. 721 00:38:50,320 --> 00:38:53,720 I mean, this bottle was actually dug up on the Somme battlefield. 722 00:38:53,720 --> 00:38:56,040 As you'd expect, as soon as they'd finished drinking it, 723 00:38:56,040 --> 00:38:57,400 the fellas just threw them away, 724 00:38:57,400 --> 00:38:59,840 and an enormous quantity of these still just turn up, 725 00:38:59,840 --> 00:39:02,680 still laying in the mud where they've been for a century. 726 00:39:05,920 --> 00:39:08,160 But things were about to change. 727 00:39:08,160 --> 00:39:11,360 When the Americans joined the Great War in 1917, 728 00:39:11,360 --> 00:39:14,600 they brought with them George Washington instant coffee - 729 00:39:14,600 --> 00:39:18,440 named after its recent inventor, rather than the first president. 730 00:39:20,040 --> 00:39:24,040 So, here we have George Washington brand, 731 00:39:24,040 --> 00:39:26,880 and this is a very, very different thing to the liquid coffee 732 00:39:26,880 --> 00:39:28,360 that we've tried earlier. OK. 733 00:39:28,360 --> 00:39:31,520 So, for a start, it's proper coffee with proper caffeine in it. 734 00:39:31,520 --> 00:39:33,720 That's going to make a difference, hopefully! 735 00:39:33,720 --> 00:39:35,600 So, it was made by basically making coffee 736 00:39:35,600 --> 00:39:38,280 and then evaporating the water off and tinning the powder. 737 00:39:38,280 --> 00:39:39,640 Oh, let's try this then. 738 00:39:39,640 --> 00:39:41,080 See if it tastes any better. 739 00:39:41,080 --> 00:39:42,120 Let's try some. 740 00:39:46,960 --> 00:39:49,200 Yeah. You'd know it was coffee. 741 00:39:49,200 --> 00:39:51,720 It's not great coffee, but you'd know it was coffee. 742 00:39:51,720 --> 00:39:54,120 And you'd... If there's a bit of a caffeine lift, as well, 743 00:39:54,120 --> 00:39:55,240 I'm sure that was helpful. 744 00:39:55,240 --> 00:39:58,000 Oh, absolutely. And what do the American soldiers think of it? 745 00:39:58,000 --> 00:40:00,200 Well, it was very, very popular. 746 00:40:00,200 --> 00:40:03,120 In fact, here's a letter from an American soldier. 747 00:40:03,120 --> 00:40:05,960 "I'm very happy, despite the rats, the mud, the draughts, 748 00:40:05,960 --> 00:40:08,240 "the roar of the cannon and the scream of the shells. 749 00:40:08,240 --> 00:40:10,560 "It takes only a moment to light my little oil heater 750 00:40:10,560 --> 00:40:12,680 "and make some George Washington coffee. 751 00:40:12,680 --> 00:40:15,440 "Every night I offer up a special petition to the health 752 00:40:15,440 --> 00:40:17,080 "and wellbeing of Mr Washington." 753 00:40:17,080 --> 00:40:19,320 It became so popular that they even nicknamed it, 754 00:40:19,320 --> 00:40:21,000 they'd call it a cup of George. 755 00:40:21,000 --> 00:40:22,600 A cup of George! A cup of George. 756 00:40:22,600 --> 00:40:23,640 Cup of George! 757 00:40:26,160 --> 00:40:28,560 By the time the Second World War came round, 758 00:40:28,560 --> 00:40:31,920 American brands like Nescafe and Maxwell House 759 00:40:31,920 --> 00:40:34,920 had refined instant coffee manufacturing techniques. 760 00:40:37,120 --> 00:40:39,880 Sachets of this new, improved coffee powder 761 00:40:39,880 --> 00:40:42,680 were put in all the ration packs of the GI Joes 762 00:40:42,680 --> 00:40:46,520 and became so synonymous with American soldiers 763 00:40:46,520 --> 00:40:50,920 that the name changed from a cup of George to a cup of Joe. 764 00:40:50,920 --> 00:40:54,200 So, as well as thanking the Americans for supporting us 765 00:40:54,200 --> 00:40:57,760 in two world wars, it seems that we also owe them gratitude 766 00:40:57,760 --> 00:41:00,400 for the mass production of instant coffee. 767 00:41:09,760 --> 00:41:13,000 In Derbyshire, we've now got coffee granules... 768 00:41:13,000 --> 00:41:14,360 ..but they're still frozen. 769 00:41:15,960 --> 00:41:19,760 It's time to put the dry into this freeze-dried coffee. 770 00:41:21,800 --> 00:41:25,360 The granules emerge from the freezer in shallow trays. 771 00:41:25,360 --> 00:41:29,720 Each one holds 15 kilos, enough for 75 jars. 772 00:41:31,760 --> 00:41:36,840 They head into an airlock and are fed into a gigantic vacuum chamber, 773 00:41:36,840 --> 00:41:39,240 where all the air has been sucked out. 774 00:41:40,960 --> 00:41:43,880 This extreme low-pressure environment 775 00:41:43,880 --> 00:41:47,680 is the same as sending our coffee 60 miles into space. 776 00:41:51,480 --> 00:41:55,520 Please explain to me why it needs to be at that pressure. 777 00:41:55,520 --> 00:41:57,360 OK. The reason it's at that pressure, 778 00:41:57,360 --> 00:41:58,600 we need to go from a solid, 779 00:41:58,600 --> 00:42:01,200 which is the ice which we've formed in the Cold Room, 780 00:42:01,200 --> 00:42:02,880 to a vapour. 781 00:42:02,880 --> 00:42:04,560 Now, we need to do that so rapidly 782 00:42:04,560 --> 00:42:06,440 that we don't go back to a water phase, 783 00:42:06,440 --> 00:42:09,400 otherwise you'll end up with concentrated liquor again. 784 00:42:13,000 --> 00:42:17,360 The dryer is heated up, which melts the ice within the granules... 785 00:42:18,400 --> 00:42:22,120 ..but in the vacuum, the ice turns immediately into a gas, 786 00:42:22,120 --> 00:42:24,320 without going through a liquid phase. 787 00:42:25,520 --> 00:42:28,320 It's a process called sublimation. 788 00:42:29,400 --> 00:42:33,200 So, the water is coming out of our icy coffee... 789 00:42:33,200 --> 00:42:35,440 That's correct. ..in vapour... 790 00:42:35,440 --> 00:42:40,400 Yes. ..leaving behind the frozen, dried coffee bits? 791 00:42:40,400 --> 00:42:43,280 At that point, it's no longer frozen, it's just a dry coffee bit. 792 00:42:44,640 --> 00:42:48,320 And you've got three of these Jules Verne submarines operating at once. 793 00:42:48,320 --> 00:42:49,880 That's correct. 794 00:42:49,880 --> 00:42:52,080 Every day? Every day. 795 00:42:52,080 --> 00:42:53,760 Every hour? Every hour. 796 00:42:53,760 --> 00:42:55,600 Never stops? Never stops. 797 00:42:55,600 --> 00:42:58,200 So that we can have a cup of coffee 798 00:42:58,200 --> 00:43:01,000 made by pouring boiling water on it? Exactly. 799 00:43:03,280 --> 00:43:04,840 Do you take sugar? No. 800 00:43:05,840 --> 00:43:07,960 Do you dunk a biscuit? Oh, I like a biscuit. 801 00:43:11,400 --> 00:43:14,640 It takes three hours for the coffee to travel through the dryer. 802 00:43:16,760 --> 00:43:17,800 Right. 803 00:43:18,840 --> 00:43:20,600 So, the coffee's dried. 804 00:43:20,600 --> 00:43:22,720 So, what is happening to it right now? 805 00:43:22,720 --> 00:43:24,000 We empty the trays. 806 00:43:24,000 --> 00:43:26,920 It just rotates the tray round, gives it a knock. 807 00:43:26,920 --> 00:43:30,800 All that coffee will fall down and that goes into a big bag below. 808 00:43:30,800 --> 00:43:34,080 Now, that's the sort of technology I can understand. 809 00:43:34,080 --> 00:43:35,120 Great! 810 00:43:35,120 --> 00:43:39,360 I like the way the two hammers come over and hit the trays! 811 00:43:39,360 --> 00:43:41,600 If I was going to be a machine in here, I'd be that one. 812 00:43:42,840 --> 00:43:44,000 Come on, then. 813 00:43:44,000 --> 00:43:45,120 Here it goes. 814 00:43:45,120 --> 00:43:46,800 HAMMER THUDS Boing! 815 00:43:46,800 --> 00:43:51,520 11 hours and 37 minutes ago, we had green beans. 816 00:43:51,520 --> 00:43:55,120 Now, we've got freeze-dried instant coffee. 817 00:43:57,040 --> 00:44:01,240 The granules fall down a chute into the room below. 818 00:44:01,240 --> 00:44:05,000 Once the bag is full of coffee, it's transferred to the filling area... 819 00:44:06,280 --> 00:44:08,560 ..where Dawn Thompson is waiting for me. 820 00:44:10,160 --> 00:44:12,200 Dawn, can I come up? 821 00:44:12,200 --> 00:44:13,240 Come on up. 822 00:44:14,680 --> 00:44:15,720 Right. 823 00:44:15,720 --> 00:44:18,920 Now, Dawn, we are just about to put coffee into jars, aren't we? 824 00:44:18,920 --> 00:44:20,960 We are. So, what we're going to do now, shortly... 825 00:44:20,960 --> 00:44:22,600 Don't call me Shortly. SHE LAUGHS 826 00:44:22,600 --> 00:44:25,080 We're going to release this bag of coffee. 827 00:44:25,080 --> 00:44:27,280 OK, would you like to do this next step? 828 00:44:27,280 --> 00:44:29,480 How much coffee is in this bag? 829 00:44:29,480 --> 00:44:30,800 450 kilos. 830 00:44:30,800 --> 00:44:33,360 Half a tonne. How many jars does that make? 831 00:44:33,360 --> 00:44:36,440 Around 2,250 jars of coffee. 832 00:44:36,440 --> 00:44:39,640 And so, all the technical stuff I've seen, all the space-age stuff, 833 00:44:39,640 --> 00:44:41,760 I'm going to empty it now by pulling the string? 834 00:44:41,760 --> 00:44:43,160 Yeah, the cord. Is that right? 835 00:44:43,160 --> 00:44:44,200 Yes. 836 00:44:46,360 --> 00:44:47,400 It's coming. 837 00:44:51,800 --> 00:44:55,440 We've got granules, but they don't smell like the coffee I know. 838 00:44:56,760 --> 00:44:59,480 That's because the aroma we stored earlier 839 00:44:59,480 --> 00:45:01,360 still needs to be put back in. 840 00:45:02,440 --> 00:45:04,120 This is the last part of the process, 841 00:45:04,120 --> 00:45:06,840 where we actually put the in-jar aroma back in before filling. 842 00:45:06,840 --> 00:45:09,160 In-jar aroma? In-jar aroma! Why'd you do that? 843 00:45:09,160 --> 00:45:11,520 Just so that we get that powerful smell? 844 00:45:11,520 --> 00:45:13,480 Yeah, so when you open that jar of coffee, 845 00:45:13,480 --> 00:45:14,960 you get that nice coffee smell. 846 00:45:14,960 --> 00:45:17,400 Do you just spray it on the top of the jars, or...? 847 00:45:17,400 --> 00:45:20,840 It gets sprayed onto the coffee as it's going into the filling room. 848 00:45:20,840 --> 00:45:24,760 The granules get a good blast of that familiar coffee aroma 849 00:45:24,760 --> 00:45:26,240 on their way down. 850 00:45:27,800 --> 00:45:30,840 So, can you take me and show me what happens to this now? 851 00:45:30,840 --> 00:45:33,320 Of course. It'd be my pleasure. Go on, you go first. 852 00:45:33,320 --> 00:45:34,360 Thank you, Dawn. 853 00:45:40,280 --> 00:45:44,600 Coffee is grown in over 50 countries around the world, 854 00:45:44,600 --> 00:45:49,560 and more than 125 million people rely on it for their livelihood... 855 00:45:51,960 --> 00:45:54,760 ..but the future of the coffee plant could be at risk. 856 00:45:56,360 --> 00:45:58,040 Cherry's at Kew Gardens, 857 00:45:58,040 --> 00:46:01,440 home to the world's largest botanical collection, 858 00:46:01,440 --> 00:46:03,000 to meet Dr Aaron Davis. 859 00:46:04,400 --> 00:46:07,120 He's just returned from a fact-finding mission 860 00:46:07,120 --> 00:46:10,520 to one of the world's largest coffee-producing countries, 861 00:46:10,520 --> 00:46:12,080 Ethiopia. 862 00:46:12,080 --> 00:46:13,800 CHERRY: Hi, Aaron, lovely to meet you. 863 00:46:13,800 --> 00:46:16,920 Really nice to meet you, Cherry. So, is this the coffee plant? 864 00:46:16,920 --> 00:46:18,880 Yes, this is arabica coffee. 865 00:46:18,880 --> 00:46:21,560 OK. It's arabica coffee that we love to drink. 866 00:46:21,560 --> 00:46:24,600 What have you discovered about what's going on with the plant 867 00:46:24,600 --> 00:46:25,880 at the moment? 868 00:46:25,880 --> 00:46:28,440 What we wanted to understand is how climate change 869 00:46:28,440 --> 00:46:30,800 is going to affect coffee across this century - 870 00:46:30,800 --> 00:46:32,600 and it's not good news, I'm afraid. 871 00:46:32,600 --> 00:46:36,880 In many cases, we've seen arabica dying in Ethiopia, through drought. 872 00:46:36,880 --> 00:46:38,400 Completely? Completely. 873 00:46:38,400 --> 00:46:41,520 And I'm talking about hundreds, even thousands, of hectares. 874 00:46:43,400 --> 00:46:46,760 It's time to wake up and smell the coffee. 875 00:46:46,760 --> 00:46:51,080 Rising temperatures and droughts are causing harvests to fail. 876 00:46:51,080 --> 00:46:55,480 Aaron's expedition data is being mapped by his colleague Justin Moat, 877 00:46:55,480 --> 00:46:59,400 in order to predict which coffee-growing areas are at risk. 878 00:47:00,880 --> 00:47:02,360 Hi, Justin. 879 00:47:02,360 --> 00:47:04,760 So, what does that map show us? 880 00:47:04,760 --> 00:47:06,680 Yes, so this is basically a spatial model. 881 00:47:06,680 --> 00:47:09,280 So, the green areas represent where good climate, 882 00:47:09,280 --> 00:47:11,200 good conditions for coffee growth are, 883 00:47:11,200 --> 00:47:12,640 and we can look at the present day, 884 00:47:12,640 --> 00:47:14,760 but we can also project this towards the future, 885 00:47:14,760 --> 00:47:16,680 so we can see immediately these areas gone. 886 00:47:16,680 --> 00:47:18,520 Why does it keep moving? 887 00:47:18,520 --> 00:47:19,840 Temperatures are increasing, 888 00:47:19,840 --> 00:47:22,040 but also rainfall patterns are changing, as well. 889 00:47:22,040 --> 00:47:24,080 So, the only places that coffee will enjoy 890 00:47:24,080 --> 00:47:25,960 will be higher up, higher elevations. 891 00:47:25,960 --> 00:47:29,680 This data is helping coffee farmers plan for the future. 892 00:47:29,680 --> 00:47:32,000 Would you say that people are responding to this? 893 00:47:32,000 --> 00:47:35,120 What we're actually seeing now is farmers going in at some altitudes 894 00:47:35,120 --> 00:47:36,200 we've never seen before. 895 00:47:36,200 --> 00:47:38,720 They've moved to the fields that are a bit higher up the hill, 896 00:47:38,720 --> 00:47:40,280 and they've moved again and again. 897 00:47:40,280 --> 00:47:42,800 Problem is, there's only so high you can go. 898 00:47:42,800 --> 00:47:44,440 Eventually, yep, we'll go off the top 899 00:47:44,440 --> 00:47:46,560 if we carry on with these temperature increases. 900 00:47:46,560 --> 00:47:49,680 And actually coffee will be the last of our problems. 901 00:47:49,680 --> 00:47:51,000 It certainly will be. 902 00:47:51,000 --> 00:47:53,400 These hotter, drier conditions 903 00:47:53,400 --> 00:47:56,080 will have an impact on coffee worldwide. 904 00:47:56,080 --> 00:48:01,000 So, the search is on to find a more resilient species of the plant. 905 00:48:01,000 --> 00:48:03,560 Aaron is delving into Kew's archives, 906 00:48:03,560 --> 00:48:05,920 to see if solutions for the future 907 00:48:05,920 --> 00:48:08,640 can be found in the records of the past. 908 00:48:08,640 --> 00:48:10,840 This place is amazing! 909 00:48:10,840 --> 00:48:14,080 What's in here? This is Kew's Herbarium, 910 00:48:14,080 --> 00:48:18,040 home to around 7 million dried plant specimens. 911 00:48:23,320 --> 00:48:26,800 How is looking through these old specimens going to help you 912 00:48:26,800 --> 00:48:29,120 solve the future of coffee? 913 00:48:29,120 --> 00:48:31,920 Within these specimens, there is lots of information, 914 00:48:31,920 --> 00:48:34,440 and information which you cannot find anywhere else. 915 00:48:34,440 --> 00:48:38,640 Let me give you an example. We have a coffee here from East Africa. 916 00:48:38,640 --> 00:48:40,240 We know this is a dry area. 917 00:48:40,240 --> 00:48:42,960 Collected almost exactly 100 years ago. 918 00:48:42,960 --> 00:48:45,320 It says here the beans are harvested 919 00:48:45,320 --> 00:48:48,360 from both wild and cultivated bushes... Yes. 920 00:48:48,360 --> 00:48:52,040 ..and fetch a high price on the European markets. 921 00:48:52,040 --> 00:48:54,520 So, it was sold in Europe? 922 00:48:54,520 --> 00:48:57,600 Yet we know almost nothing about this coffee. 923 00:48:57,600 --> 00:49:00,800 If that coffee plant can cope with conditions 924 00:49:00,800 --> 00:49:04,880 where there isn't a lot of water, and it tastes amazing... 925 00:49:04,880 --> 00:49:07,000 Yes. Then, there's your answer. 926 00:49:07,000 --> 00:49:09,560 That's the moon-shot, that's the dream. 927 00:49:09,560 --> 00:49:11,720 We've actually managed to acquire a sample. 928 00:49:11,720 --> 00:49:14,400 We have some roasted that we can go and try now. 929 00:49:14,400 --> 00:49:16,440 That's very, very exciting. 930 00:49:16,440 --> 00:49:18,840 Let's go and have a very exclusive cup of coffee. 931 00:49:23,760 --> 00:49:25,200 Cheers. Cheers. 932 00:49:25,200 --> 00:49:26,240 To coffee's future. 933 00:49:30,360 --> 00:49:32,160 What is that funny taste? 934 00:49:32,160 --> 00:49:35,880 You're right. It's a herby, sort of eucalyptusy... 935 00:49:35,880 --> 00:49:39,880 I don't think this coffee is the ultimate solution, 936 00:49:39,880 --> 00:49:43,760 but with 125 known species recorded in the archive, 937 00:49:43,760 --> 00:49:45,600 Aaron remains hopeful. 938 00:49:45,600 --> 00:49:47,320 So, what is the dream? 939 00:49:47,320 --> 00:49:50,320 What would you absolutely love to discover? 940 00:49:50,320 --> 00:49:52,480 What we would really love to discover 941 00:49:52,480 --> 00:49:54,560 is a climatically-tolerant coffee 942 00:49:54,560 --> 00:49:58,000 that tastes as good, or perhaps even better, than arabica. 943 00:49:58,000 --> 00:49:59,640 Are you looking for magic beans? 944 00:49:59,640 --> 00:50:01,800 We are. Good luck. Thank you. 945 00:50:18,520 --> 00:50:20,960 GREGG: Back in the factory, we've prepared the coffee. 946 00:50:22,040 --> 00:50:24,240 Now, we need to get the jars ready. 947 00:50:25,840 --> 00:50:29,520 Wow! That is a big heap of glass jars. 948 00:50:29,520 --> 00:50:32,400 Can you guess how many jars are on that pallet? 949 00:50:32,400 --> 00:50:34,240 Er, 600. 950 00:50:34,240 --> 00:50:37,280 1,694 jars are on that pallet. 951 00:50:37,280 --> 00:50:39,560 I got the 600 bit right! You did, yeah. 952 00:50:45,160 --> 00:50:48,040 I love this stuff. I'm an absolute sucker for this stuff. 953 00:50:48,040 --> 00:50:51,120 I could watch this all day long. What is happening? 954 00:50:51,120 --> 00:50:53,000 So, the four crampons come in, 955 00:50:53,000 --> 00:50:55,480 sweep it lovingly onto the conveyor belt. 956 00:50:55,480 --> 00:50:56,520 So, very much the same 957 00:50:56,520 --> 00:50:58,760 as if I have to carry three pints back from the bar. 958 00:50:58,760 --> 00:51:00,520 I've got two, I've got one in each hand. 959 00:51:00,520 --> 00:51:02,680 If I have three, I've got them squeezed together. 960 00:51:02,680 --> 00:51:05,240 That's what that's doing. You have to try carrying four in each 961 00:51:05,240 --> 00:51:07,400 and see how far you can get. It must break some. 962 00:51:07,400 --> 00:51:08,680 No, very rarely. 963 00:51:08,680 --> 00:51:11,680 Because it's such light pressure, it carries the jars across. 964 00:51:13,520 --> 00:51:16,280 300 jars a minute shuffle along the conveyor... 965 00:51:18,120 --> 00:51:21,240 ..and are gently encouraged into position. 966 00:51:21,240 --> 00:51:23,120 Oh, they're all getting a bit bunched up here. 967 00:51:23,120 --> 00:51:24,800 This is why it's called the combiner. 968 00:51:24,800 --> 00:51:27,840 So, as they come off the bed, they bunch together. 969 00:51:27,840 --> 00:51:29,640 You deliberately create this curve. 970 00:51:29,640 --> 00:51:32,280 Yes. So that the batches of jars catch up with each other. 971 00:51:32,280 --> 00:51:33,760 Yes. 972 00:51:33,760 --> 00:51:35,640 Come on, jars. Come on. 973 00:51:36,880 --> 00:51:38,000 Come on, little jars. 974 00:51:41,040 --> 00:51:43,280 How are they moving into single file? 975 00:51:43,280 --> 00:51:45,600 I can understand the jars on the inside lane, 976 00:51:45,600 --> 00:51:48,480 but the ones on the outside, they look like they're actually 977 00:51:48,480 --> 00:51:51,760 trying to push their way in the dinner queue, how does that happen? 978 00:51:51,760 --> 00:51:53,680 They just can't wait to be filled. 979 00:51:53,680 --> 00:51:56,600 However, the belt speeds are different to the ones on the corner, 980 00:51:56,600 --> 00:51:59,720 so they'll basically push themselves into single file. 981 00:51:59,720 --> 00:52:01,880 With different belt speeds? Yes. 982 00:52:03,440 --> 00:52:07,320 Now in an orderly queue, the jars glide to the next machine. 983 00:52:08,840 --> 00:52:11,080 Something's getting hold of them and twisting them, 984 00:52:11,080 --> 00:52:12,800 making them straight. Yeah. Why? 985 00:52:12,800 --> 00:52:14,760 Because, as we go into the orientator, 986 00:52:14,760 --> 00:52:16,080 we don't want them twisted. 987 00:52:16,080 --> 00:52:18,240 The what? The orientator. 988 00:52:18,240 --> 00:52:20,040 What's an orientator? 989 00:52:20,040 --> 00:52:22,880 The jars are coming into the machine, 990 00:52:22,880 --> 00:52:24,720 they're not really in the correct format. 991 00:52:24,720 --> 00:52:26,200 So they're back to front. 992 00:52:26,200 --> 00:52:28,240 But you're going to fill them up with coffee 993 00:52:28,240 --> 00:52:29,640 and stick a lid on them, right? 994 00:52:29,640 --> 00:52:34,240 Why does it matter if they're not all exactly the same way round? 995 00:52:34,240 --> 00:52:37,160 We have to make sure the label gets put on the right way on the jar. 996 00:52:40,000 --> 00:52:42,920 It looks like the end of the line might be a cliff-hanger. 997 00:52:44,280 --> 00:52:46,200 They're going over the edge. 998 00:52:46,200 --> 00:52:47,520 It's like a big dipper. 999 00:52:47,520 --> 00:52:50,480 I just imagine them, all the funfair, going, 1000 00:52:50,480 --> 00:52:52,240 "Ahhhhh!" 1001 00:52:54,840 --> 00:52:56,960 So, are we finally going to put coffee in them, Dawn? 1002 00:52:56,960 --> 00:53:00,080 Finally. Come on. Show me. 1003 00:53:00,080 --> 00:53:01,280 Brilliant factory. 1004 00:53:02,520 --> 00:53:04,560 FUNFAIR MUSIC PLAYS 1005 00:53:07,320 --> 00:53:10,000 CHILDREN ON RIDE SHOUT 1006 00:53:15,000 --> 00:53:19,080 12 hours and 42 minutes into the production process, 1007 00:53:19,080 --> 00:53:21,080 coffee meets jar. 1008 00:53:23,200 --> 00:53:26,000 It's a nice sight, isn't it, actually? 1009 00:53:26,000 --> 00:53:27,440 Lovely. Look at that. 1010 00:53:29,600 --> 00:53:33,920 This machine fills 280 jars a minute. 1011 00:53:33,920 --> 00:53:39,080 It'll take more than 11 hours to get through today's batch of 175,000. 1012 00:53:42,280 --> 00:53:46,080 The caps are on - but hang on, where's the gold seal? 1013 00:53:48,240 --> 00:53:50,280 As you can see, when we open this jar up, 1014 00:53:50,280 --> 00:53:52,800 it doesn't have the seal across the top you're used to seeing 1015 00:53:52,800 --> 00:53:56,440 when you open a jar properly. The seal is actually in here. 1016 00:53:56,440 --> 00:53:59,480 So, the seal is already in the lid. 1017 00:53:59,480 --> 00:54:01,200 That's correct, yes. 1018 00:54:01,200 --> 00:54:03,720 And that machine does what to the lid? 1019 00:54:03,720 --> 00:54:07,120 It actually seals the membrane to the top of the jar. 1020 00:54:07,120 --> 00:54:08,680 Through the lid? Through the lid. 1021 00:54:10,200 --> 00:54:14,600 The plates above the jars work like upside-down hotplates. 1022 00:54:14,600 --> 00:54:19,480 They heat the foil to 80 Celsius, hot enough to melt the glue, 1023 00:54:19,480 --> 00:54:22,440 releasing the foil down onto the glass 1024 00:54:22,440 --> 00:54:24,960 without melting the lid itself. 1025 00:54:24,960 --> 00:54:26,680 That's remarkable. 1026 00:54:26,680 --> 00:54:30,400 That's one of the most mysterious things I've ever seen in a factory. 1027 00:54:36,280 --> 00:54:37,400 I recognise that. 1028 00:54:39,600 --> 00:54:43,640 That is a beautiful roasting coffee smell. 1029 00:54:43,640 --> 00:54:45,760 It does seem strange you had to take the smell out 1030 00:54:45,760 --> 00:54:47,720 and put it back in again. 1031 00:54:47,720 --> 00:54:49,080 Clever. 1032 00:54:49,080 --> 00:54:50,680 Dawn, thank you. 1033 00:54:50,680 --> 00:54:53,520 Can I say, for all the amazing processes in this factory, 1034 00:54:53,520 --> 00:54:54,880 this has been the most fun. 1035 00:54:54,880 --> 00:54:55,920 Come here. 1036 00:54:57,160 --> 00:54:58,560 Thank you very much. My pleasure. 1037 00:55:01,200 --> 00:55:03,960 Now it's time for the final steps. 1038 00:55:03,960 --> 00:55:08,000 The labels are put on the jars and they're wrapped in groups of six. 1039 00:55:09,840 --> 00:55:13,040 A shipping label is blown on... 1040 00:55:13,040 --> 00:55:17,200 ..and they're sent up a spiral conveyor for one last joyride. 1041 00:55:21,000 --> 00:55:24,280 Then robots begin an elaborate stacking routine. 1042 00:55:25,560 --> 00:55:29,160 They arrange the jars with some right angles to the others... 1043 00:55:30,400 --> 00:55:34,080 ..and squeeze them together to form a layer, 1044 00:55:34,080 --> 00:55:37,560 making sure the gap's in a different place each time. 1045 00:55:39,160 --> 00:55:43,280 This strange pattern is mathematically calculated 1046 00:55:43,280 --> 00:55:48,160 to give the 1.4m high stack stability and strength, 1047 00:55:48,160 --> 00:55:50,840 and to reduce the chance of breakages. 1048 00:55:52,240 --> 00:55:54,400 Finally, they're wrapped in cellophane. 1049 00:55:59,280 --> 00:56:05,600 13 hours and 22 minutes ago, I saw green beans arriving at the factory. 1050 00:56:05,600 --> 00:56:10,040 They've been roasted, ground, concentrated, frozen, 1051 00:56:10,040 --> 00:56:11,760 and sent into space. 1052 00:56:12,800 --> 00:56:16,520 Now transformed into freeze-dried coffee granules, 1053 00:56:16,520 --> 00:56:18,120 they're ready to leave the factory. 1054 00:56:20,040 --> 00:56:22,640 Waving them off is Clive Whitebrook. 1055 00:56:24,240 --> 00:56:27,120 That's it. That's my coffee being loaded onto the truck, Clive. 1056 00:56:27,120 --> 00:56:28,520 It is, the final pallet. 1057 00:56:28,520 --> 00:56:33,160 There is 48, which is approximately 40,000 jars, 1058 00:56:33,160 --> 00:56:37,000 which is about 4.4 million servings. 1059 00:56:37,000 --> 00:56:40,160 On that lorry is four and a half million cups of coffee. 1060 00:56:40,160 --> 00:56:42,520 Yes. How many lorries leave here every day? 1061 00:56:42,520 --> 00:56:44,000 Approximately six. 1062 00:56:44,000 --> 00:56:47,520 Wow! Quite a phenomenal process, isn't it? 1063 00:56:47,520 --> 00:56:49,960 It is. For something so relatively simple. 1064 00:56:49,960 --> 00:56:52,080 Yep. And that's what we all take for granted. 1065 00:56:54,600 --> 00:56:56,720 Full to the brim. That's it. 1066 00:56:56,720 --> 00:56:58,160 And that's ready to go, right? 1067 00:56:58,160 --> 00:57:00,320 It is. It's been quite a journey, you know. 1068 00:57:00,320 --> 00:57:04,640 From bean to jar. It's been absolutely amazing. 1069 00:57:06,280 --> 00:57:10,600 From the factory, the jars head to supermarket shelves 1070 00:57:10,600 --> 00:57:15,200 in the UK, Europe, and almost every corner of the world, 1071 00:57:15,200 --> 00:57:19,840 including coffee-producing countries Peru and Ecuador. 1072 00:57:22,400 --> 00:57:24,000 I drink instant coffee, 1073 00:57:24,000 --> 00:57:25,840 and if you'd have asked me how it was made, 1074 00:57:25,840 --> 00:57:27,480 I think I would have come up with 1075 00:57:27,480 --> 00:57:29,520 roasting the beans and grinding them - 1076 00:57:29,520 --> 00:57:34,200 but never in my wildest dreams would I ever have imagined 1077 00:57:34,200 --> 00:57:38,360 sheets of coffee frozen to -50 degrees 1078 00:57:38,360 --> 00:57:40,840 while then being dried out in machines 1079 00:57:40,840 --> 00:57:43,560 that look like Victorian steam engines. 1080 00:57:43,560 --> 00:57:48,720 Hours, and hours of complicated scientific process, 1081 00:57:48,720 --> 00:57:52,880 so that you and I can make a cup of coffee in seconds. 1082 00:58:00,640 --> 00:58:02,800 Next time, we're in Manchester, 1083 00:58:02,800 --> 00:58:06,400 inside one of the largest toilet paper factories in the UK. 1084 00:58:07,520 --> 00:58:11,880 If King Kong used toilet paper, that would be the one he used. 1085 00:58:11,880 --> 00:58:14,480 Where five and a half million loo rolls 1086 00:58:14,480 --> 00:58:17,960 roll off the end of the production line every week. 1087 00:58:17,960 --> 00:58:19,240 There we are. 1088 00:58:20,600 --> 00:58:24,320 And Cherry has a cheeky encounter... 1089 00:58:24,320 --> 00:58:27,120 Oh! What is that?! 1090 00:58:27,120 --> 00:58:28,600 ..with a futuristic loo.